Process for manufacturing beryllium



. Flesrsrsmr nlvazsowl/ve 465N7- Jan. 20, 1942.

J. E. BUCHER 2,270,502

PROCESS FOR MANUFACTURING BERYLLIUM Original Filed July 18, 1933 i 58 e INVENTOR J19 v BY W AW Patented Jan. 20, 1942 UNITED STATES 2,210,502 P OCESS FOR mnurscrunmc BEBYLLIUM .l'ohn E. Bucher, Fort Lee, N.'J., assignor, by mesne assignments, to Antioch College of Yellow Springs, Yellow sm' nta'flhio, a corporation of Ohio Continuation of application Serial Nmcsosza, filed July 18, 1933. This application February 25,1937, Serial No. 127,791

24 Claims.

The preparation of beryllium from its halogen compounds by means of alkali or alkaline-earth metals as well asby means of the electric current, has been known for a long time. The finely divided metal thus obtained is very likely to be' contaminated with oxides, hydroxides, nitrides. silica, etch The principal ways in which these impurities enter is through the use of impure beryllium oxide for the preparation of the halogen com-' pounds; from the halogenizing agents 'as wellas from attack oi. the walls or the apparatus used in the process; from the moisture, oxygen and nitrogen of the air and irom impurities introduced during the prccess of recovering the finely divided metal by leaching out halogen salts of the alkali or alkaline earth metals. These troubles are especially noticeable with beryllium chloride. Further impurities may be introduced in the subsequent treatment of the. metal to obtain either a regulus or alloys. I

'Evenwhen the powdered metal is briquetted and fused in an atmosphere of hydrogen, it should contain at least 80% of pure beryllium in order to enable the particles to be fused or run together when heated.

If hydrogen'is'present in the reagents used for changing beryllium oxide into a halogen salt, such as a chloride, it may form water with a portion of the oxygen of the beryllium oxide.

especially the chloride are decomposed with violence when they are brought into contact with water, hence it is advisable to exclude moisture as well as hydrogen very carefully. For the same reason, hydrogen compounds such as hydroxides, ammonium salts, hydrochloric acid, etc., should be excluded from the halogenating or chlorinatparticles of beryllium with water is entirely eliminated and the process is improved so as to eliminate the above mentioned difllculties. Also.-

beryllium alloys maybe prepared by this invention without the necessity of first isolatlng the pure beryllium by leaching with water, or otherwise.

Beryllium oxide may be prepared by any convenient method for use in obtaining the halogen The halogen compounds of beryllium and compound of beryllium or beryllium chloride for use in this invention, but. I prefer for this purpose to "open" the beryl with lime and extract with'sulphuric acid as set forth in my copending 5 application, Serial No. 632,641, 1932 now Patent 2,010,844, issued August 13, 1935, and thus ob-' tain the beryllium oxide. In this process of preparing the beryllium, the beryllium is finally precipitated as basic beryllium carbonate which,

10 upon heating, loses water, carbon dioxide, am-

monium salts and in some cases perhaps sulphur dioxide and trioxide to leave a residue of beryllium oxide.

'It has been found that when beryllium oxide 5 isprepared from the carbonate at a low temperature it is-more reactive than when it is highly ignited and therefore it-is advisable or preterable to prepare the beryllium oxide at a rather low temperature so as to have the advantage of greater speed in the chlorinating or halogenating step or process. Temperatures down to 400 C. for chlorinating have-been described heretotore but the dangers or troubles arising from residual water in this procedure do not appear to have been obviated.

The present invention will be specifically described-inconnection with the use of a chlorinating step in the process, but other halogens may be used in a similar manner. In carrying out this invention. to make beryllium chloride from the oxide'chlorine. or something which caniurnish chlorine must be present, and some element such as sulphur or carbon or something capable of furnishing such element should also be present to combine with the oxygen to furnish energy and to eliminate oxygen as 00:, S02, etc.

These reagents may, however, contain substances which cause trouble. For example, chlorlnating a heated mixture or BeO and sugar 40 charcoal iswell known but the charcoal still contains a considerable amount of hydrogen and oxygen. even after long heating to redness. This causes the formation oi water which in turn may contaminate the resulting chloride with enough 5 oxide to interfere greatly with its usefulness in the preparation of beryllium metal and alloys. Another well known method is to chlorinate beryl lium oxide with a mixture or chlorine and carbon monoxide. In case the carbon monoxide is produced by the very convenient method oi heating formic acid with either strong sulphuric or. phosphoric acids, some-hydrogen will always be present which will lead to the formation or weterandthlist'o'thetormationofBeOinthe condensed beryllium chloride. This is true even tamination of the recovered metal with'oldde.

By the present invention diiiiculties are overcome which may have been due to reversibility of the chlorinating reaction or to other causesand, at the same time, the introduction of certain impurities, especially silica or silicates that might be formed by attack of beryllium chloride or oxide) upon the walls of the reaction vessel,

such as glass, silica porcelain, fire clay, etc.. is

avoided.

My process will now be described in connec 'tion with the accompanying drawings in which Fig. 1 -is .a diagrammatic representation of an apparatus which is suitable for large scale manui'acturing operation and which requires very little attention after it is adjusted at the start,

and Fig. 2 is a sectional view on an enlarged scale of one of the parts.

In the drawings, the rectangular spaces, enclosed by the dotted lines designated by the letters A, B, C, D, E, F; and G represent diagrammatically heat regulators or furnaces which can be heated or the temperatures thereof regulated in any suitable way to the respective temper-.

atures required by the operations to be conducted therein.

Reference character I indicates a vertical elongated retort located in the furnace A. The retort I is provided with a removable cover 2 at the top and a grate 8 near the bottom for sup-- porting a charge of solid material to be treated, which may be beryllium oxide briquettes. An outlet 4 from the retort I is provided below the grate 3 for removing residues.

An inlet gas pipe 5 provided with a valve 6 enters the bottom of retort I below the grate 3, and a gas pipe I provided with a valve 8 enters this retort intermediate its ends, preferably near the middle thereof.

A valved water pipe I leads to a constant level water reservoir II that is provided with an overflow I2. A pipe I3 that is provided with a needle valve I4 leads from the reservoir II to a small tank I5, from the bottom of which a pipe I6 leads through the sight glass II. The upper end of the pipe I6 terminates above the bottom of the tank I and a cap I8 is provided over the upper end of the pipe IS. The cap has a serrated edge I9 that rests upon the bottom of the tank I5 so that any sediment may settle in the bottom of this tank without-entering the pipe I8.

The lower. end of the pipe I6 passes into a retort that is located in the furnace B. This furnace is provided with checker brickwork 2| and also with a safety exitpipe 22 that-extends into a column of water in the water seal cylinder 23. A valved gas inlet p pe 24 leads'into the lower portion of the retortfl'tl. A gas and'vapor and a valved outlet 29 is provided at the lower portion of the receiver 28 for the removal of condensates. A gas outlet pipe 30 having a needle valve 3| therein is provided at the upper portion of the receiver 28.

An outlet 33 from the retort I is located a short distance below the gas inlet pipes I and 25, and leads to a. condenser 34 which is located in the heat regulator C so that its temperature can be maintained at the desired point.

- A liquid trap 35, to prevent passage of gases, is connected by the pipe 36' to the lower side of the condenser 34.- A connection 31, providing a longer liquid column than the connection 36, leads from the liquid trap to the retort or still 38 located in the furnace D.

An outlet 39 for gases or vapors, located in a heat regulator E, leads from the upper side of the condenser 34 to a dust collecting chamber 40. A vertical baifle 4I is provided in the chamber 40 and an outlet 42 for solids is provided at the bottom of this chamber. Ages and vapor outlet 44 is provided at the upper portion of the chamber 40 on the other side of the baflle H from the inlet 39. This outlet 44 le'ads'to a water sealed chamber 65 having 'a' gas exit 46 leading therefrom.

An outlet pipe 48 located in a heat regulator F leads from the still-38 to a condenser and reservoir 48 that is located in the heat regulator G. An inlet pipe 50 for gases provided with a stop cock II enters the upper portion of the receiver menu a gas-tight removable cover 52 is provided at the upper end of this receiver. 'A liquid trap 53 is connected to the lower end of the receiver 49 and is provided with an outlet 64 having a flange to which a closure 53. may be connected.

A receptacle SS-(Flg. 2) has change 56 that can be connected to the outlet 54 so as to form a tight joint. A closure 56 is provided for the flange 56. Inlet and outlet pipes 51 and 58 are provided for the receptacle so that a gas can be circulated through this receptacle. A support 5! of refractory material, such as fire brick, is provided in the receptacle 55 for a crucible or crucibles 60 which may be of metal, such as iron, nickel or copper, for example. A graphite crucible BI is placed in each crucible 60. A coating 62 of magnesia should be placed between the crucibles 60 and GI when the crucible 60 is made of iron, to preventformatlon of iron-graphite eutectic. A lining 63 of metal that is to be alloyed with beryllium, preferably in the shape of a cone, is provided for the crucible BI.

The apparatus may be operated either for batch runs or' as a continuously operating plant.

For a batch run, the retort I may be filled with briquettes of beryllium oxide stlil containing some moisture, ammonium salts and sulphates, or the briquetted basic beryllium carbonate itself may be used if it is not heated so fastthat the escaping steam and carbon dioxide disintegrate the briquettes.

After the briquettes have been introduced, the entire apparatus may then be filled with some suitable gas such as nitrogen or carbon monoxide. All stopcocks, valves and the outlet 54 being closed, valve II is opened to admit a gentle current' of this gas and allow it to escape by fully opening the valve 3L The furnace C is heated to 440 C. and the retort I in the furnace A is heated to any suitable temperature such as, say, 650 to 720 C. and a mixture of steam and a current of reducing gas such as carbon monoxide is passed into the retort I through inlet 5. As soon as sulphur compounds are sufliciently or completely expelled through the outlet 26 the steam is shut oil from the entering current of carbon monoxide. As soon as all of the moist gas in the briquette column in retort I has been displaced the valve 3I is closed so that-the gas will then.escape through the water trap 45.

A gentle current of carbon monoxide, chlorine, nitrogen or producer gas is then introduced through the inlet I, into the heated briquette column in retort I. Also a vigorous current consisting of about equal volumes of chlorine and carbon monoxide is passed into the retort at inlet 5. Copious formation of beryllium chloride starts immediately and passes out through the outlet 33. The chloride condenses in the condenser 34 which is kept just'above the solidifying point (about 440 C.) of BeCl, while the gases consist ing chiefly of CO: pass up through the vertical pipe 39 and escape through the outlet 45.

The hot viscous liquid BeCl: drains down from condenser 84, into the trap 35, and soon forms a gas seal so that the entry of gas at inlet 50, which is under very gentle pressure is stopped. The molten liquid in the trap 35 also prevents any gases such as C12, C0, C02, HCl, and even traces of water vapor resulting from the chlorinating process, from entering into the retort 88. In this way the CO2 is removed from the liquid beryllium chloride so that it cannot cause contamination of the Beck with BeO due to reversal of the chlorlnating reaction. This trap 35 by preventing the entry of uncombined or excess chlorine into the retort or still 38 permits the use of metals which are not attacked by beryllium chloride for construction of this retort. Copper is especially suitable for constructing this retort because of its cheapness, durability and excellent heat conductivity.

' During the run the furnace D is maintained at a temperature above the boiling-point (about 520 C.) of the beryllium chloride which therefore distills over into the condenser-receiver 49,

leaving the harmful non-volatile oxygen containing impurities such as beryllium oxide, silica, silicates, etc., in the retort 38, which may be cleaned out when desired.

The condenser 49, which is also very advantageously made of copper may be kept just above the solidifying point (about 440 C.) of BeClz when BeClz is the desired product. ,The very pure viscous liquid beryllium chloride which has a very low vapor tension may then be drawn of! through the trap 53 at 54. The operation can be continued until substantially all of the Eco briquettes have disappeared from the retort I.

Itis ordinarily much more desirable to recover the beryllium chloride in admixture with alkali These mixtures have low melting points (about 215 C. for the BeCh-NaCi eutectic mixture), and very little vapor tension and are much less hygroscopic than pure beryllium chloride. For example, sodium chloride which has been freshly ignited to expel moisture and while still hot is introduced quickly at 52 and the retort 49 is then heated to the proper temperature (about 215 C.) and then a very pure beryllium chloridesodium chloridemixture may be drawn oil at outlet 54. The composition is automatically determined by this procedure and this is very convenient in making analyses unnecessary. However, by suitably varying the temperature and rate of charging of the retort 45 with sodium chloride, substantially any composition of product between that of pure beryllium chloride and f volumes.

.chlorides such as those of sodium or potassium.

pure sodium chloride may be drawn of! at outlet 54. The temperature will be changed for a beryllium chloride-potassium chloride mixture. Such a process is described and claimed in my prior Patent No. 1,988,109.

The process may be run continuously as follows: Start as before and operate untl the briquette column in-retort I has dropped somewhat but its upper endis still considerably above the level at which the inlet 25 enters this retort. Open the cover 2 momentarily and fill up with fresh briquettes of beryllium oxide or carbonate. Open the valve 8 to admit the predetermined flow of CO (forexample, 2 liters'per minute) through thepipe land open the valve in the pipe 24 to admit thepredetennined flow of CO e (for example, one liter per minute) into the briquettecolum'n at 25 and at once open and set the calibrated valve 3| so that under conditions of the pressure in the system (determined by the depth of water in chamber 45) say two liters of gas per minute escape. Then open the valve I4 to permit water to drop. at a rate predetermined by the capillary pipe I6 onto the fire brick in the retortjo which is kept at a temperature above the boiling point of water. This insures a steady passage of steam into the retort" at 25. This steam may have a relatively highvolume but as it is again condensed in the condenser 21, it introduces no disturbance in the regulated gas Any eflfect of resistance to gas flow by the brlquette or friction in. the pipes-may readily be compensated for by the calibrated valv 8|. It the figures given as in the illustration are adhered to, all of the resulting CO: and BeCh vapets will. pass into the condenser-'34, All the steam entering at 25 will pass upwardly through the briquettes column in retort I. while the pure C0 entering through pipe I is divided. part goin through the briquettes and leaving the system at the valve II while the rest passes downwardly out through the condenser 34 and leaves the system at the outlet 48. This divisionflof the CO gas current at the inlet 1 therefore prevents any damage either from steam that is admitted or from moisture from the fresh briquettes, and at the same time it prevents BeClz vapor from passing above the point where the outlet 33 to the condenser 84 is connected to the reaction retort I. Feeding of fresh briquettes can be repeated indefinitely, thus providing continuous passage of hot purified briquettes into the top of the chlorinating zone in the retort I. the unvaporized residue if any being withdrawn at the outlet 4.

The presence of the trap 35 for the molten beryllium chloride and maintenance of the retort 38 at higher temperatures insures a pure final product even if the beryllium chloride from condenser 34 is contaminated with non-volatile trap 35 and retort I8. For the same reason whatever aqueous moisture may remain in BeO.

briquettes that have been heated only moderately so as to retain great activity and introduced into the retort I. will not prevent their-use for preparing pure beryllium chloride. The hydro- -,8en ofsuch moistureisaeliminated ,asHClin them, 7 1 it'rapgti-hm;the,oxygen isleft as l 3eO.,in the alloys, the pure beryllium chloride-sodium chloretort itw hisarranz n tn muamel e briquettes -.conta ining charcoaltora carbon, from, sugar, starch, etc, which have hotl-heenheated high enough to seriouslyiniurewtheir reactivity as any hydrogen. and-oxygen remaining. in the; charcoal eliminated .as HCl-aud --BeO- as ex- I p ed i i. 1-;-

a puriflca ,6n,,imaddition to that used in puri-.v

' r-r mv u aa nl t v ins tower o co n; Knot shownlgcontaining-sodium chloride heated Ute-a 'peia i' 'es m atabav 1. 1 Gr g5- o le l sk et, t gr om; temperature at u' ia v attice. ar aemu a l pe el sputatthepi eufi rs lected aiid the CO2 thereinma preparation of e the IBeO, if When 'the 1 a p ce w t r iii then] thelexit tilt ma fonexamplelbeused to. 1

nftetrachloride, Whea en" without other fgases suchfasj itrogen, chlorine,

' carbon monoxid'efetclj If the, reaction allowed toppro 'c'e'ed toequilibrium'in the heat zone, there willlie notroublefrom the escape of intermediate products suchas'czclgfbut even in the caseof 5o faulty operations this. compound ma be 'elim-. inated in the chamber fidbecause of its volatllity and the api -j Phosgene can be in thei same way carcorrect' proportioning of elements forth rinating reaction,

In theuse of carbon and chlorine the freactlon may be exothermiclto'such an extent that j littl e or no external heat need be supplied to theretort I, when. working pn alargefscala iln th s;case also"the lntroductionof steam at inlet' 2 5 and- CO at inletllj'sh'ould be carried out carefully as both of 'these reaientswill remove some carbonfrom the briquettes The. resulting aseswOlcoz and H2) resulting from the pro cess may be collected at the outv let a and they may be introduced, intothe system again mourn the inlet-20m such'reacdq n e 'w v i as it removes all of the above cited impurities 7 h 'carbon "and lch'lorl'ne jin' the right proportiomfm the chlorine-ting reactionmayfb'e introducedieither lasliquid'jor'jvapor through thein'let Swith or 5' For the preparation of pure berylliumv or its ride or beryllium chloride-potassium chloride collected in somev suitable apparatus for example such as isillustrated in Fig. 2.

-I prefento have a thin lining 63 made of the metal which is tobe alloyed with beryllium withinfthegraphitecrucible 6L, This lining is conveniently drawnjin a ,die or the metalmay be folded somewhat in the manner of a filter. Its objectis to prevent the molten beryllium chloride or its admixtures with alkali or alkaline earth' mezal halides from coming into contact with the "graphite. crucible, and at the same time it furpart (or even all) of the metal to be alloyed with-the beryllium,

, tmosphere of an inert gas such as argon, helium or hydrogen may be maintained by means of thesinleti'l and outlet 58 in the crucible GI and such gases shouldbe as free as possible from ,water vapor, oxygen, nitrogen, carbon dioxide,

carbon -monoxide, ammonia, sulphides, etc. Commercial hydrogen which contains a little free oxygenJnaybe passed over some contact materialat a white heat, cooled, and then dried with phosphorus pentoxide on liquid air and used for this purpose.

Argon or hydrogen, for example, may advantagmuslypunfled by. the following procedure in Ioneoperation and it is especially convenient.

A tower containing iron turnings, wool, shavings, piecespf wire, nails, etc., which expose a large 'gkjslirfaceand are still porous enough to permit flow. ofgas, is heated to-say l000- to 105 0 C. 'i The argonpr hydrogen mixed with an excess of vapor is then passed: through the incandescentcolumn and the products are then fpassed throughacooler porousmass of iron. 'fwhlch condenses volatile salts and sodium and m rs {but fumes. Thevnitrogen and carbon are removed as sodium cyanide, sulphur.is removed as sodium sulpho-cyanide or sodium sulphide and oxygen is removed as an oxide of sodium or as products such as carbonate or cyanate derived from it. l

",The receptacle 55 containing the empty crucible or crucibles is heated to about 900 to 1000" C. A current of pure hydrogen is kept flowing to remove moisture and reduce any oxides which may be present. After cooling, the receptacle 55 is attached to the flange 54 to collect U the'requisite charge of beryllium chloride-sodium bon tetrachloride and has'the same advantage of 5 ferred to a furnace and heated-until the charge is melted. Small pieces of sodium, which may prepared by forcing the sodium from a press into'an apparatus filled with pure hydrogen so a j 'an ed that the rod of sodium can be cut into 7 suitable lengths as it is extruded are dropped into the molten charge in the lining 63 of the gra'phitecrucible Bl. This procedure prevents contact of sodium with the moisture of the air and thus avoids contamination of the charge withoxygen from this source.

tions'I have-foun'dthatamixtureoffhand C0 16 4 e (water gas) may be used'ln pla'ceof steam and f" .very violent fi t, but as the percen e of in this case "only enough water would have mgj, er iu m de'm the ixtu e decr ses, the be admitted to the retort--20 to replace the hyreaction becomes less violent and the temperadrogenthat is used up chemically and reture' is gradually raised to prevent solidified salt lectedwlththe'coz.

The reaction starts below a red heat and is.

15 andthus prevent contact of need not be over above the sodium with the beryllium chloride. -I prefer to complete the run above the melting point of the halide remaining at the end of the run. This I may be somewhat above 800 C. when-sodium" chloride is used to collecttheBeCl: vapor, but

650 0. when potassium chloride is used.

-Stirring. of the contents-of the crucible 6| is described in 'order to cause the particles or spangles of metallic vberyllium-to'contact with the metal with which it is to alloy. An additional object of the above cited stirring during the addition of the sodium is to get the liberated beryllium and sodium under the surface of the molten sodium chloride, which shields them=from destructive impurities if such by remain Y in the drogen.

It is possible to so operate by adding the.

sodium in larger pieces to get a violent. reaction and the beryllium spangles may partially sinter and even form some globules. This may be aided by-keeplng the temperature low enoughiso that. some of the sodium chloride salt-solidifies as the Beck becomes used up. Ordinarily, however, I prefer to have a stout wire bent to a loop atthe lower end rotating in-the solution'until the re- Finely divided beryllium rapidly attacks clay orporcelain; but graphite crucibles; because of the low operating temperature and almost immediate removal of beryllium spangles bysolu- :tion in metals and formation of alloys such as copper and silver, give very satisfactory results. Graphite contains no oxygen (barring the almost infinitesimal oxygen content of its ash) and-is, therefore, free from the most serious trouble encountered in *the manufacture of beryllium and its alloys.

. .During the run-one of the tubes 51 and 58 of the receptacle 55 is kept closed so that the hydrogen'gas current will escape at the upper flange 56 ifthere is leakage and keep out air. When the'runhas been completed, the receptacle 55 is closed with a cover such as 'the cover 56' and .is allowed to cool under a slight positive hydrogen pressure to preventair getting in while it might still do harm.

The present invention is especially well adapted 2 for the isolation of beryllium spangles. When action is completed to cause contact of beryllium and alloying metal. a

In this way, a molten bath of sodium chloride is present in which are suspended a3.-multitude of beryllium spangles with noimpurities coating their surfaces.

In this conditionand despite their high melting point (l2"l8 C.) :they alloy-.

a; liquid the run is made as described above but the temperature is not raised above say about 820 C., copper-beryllium alloy is not formed although the surface of the copper lining shows the formation. of. a solid solution. .After cooling,

the thin copper-lining-(which remains intact) canbe lifted out and separated-from the cone of alkali chloride-spangle mixture. This can be powdered andleachedquickly to remove the chloride. In sucha casethe graphite crucible i BL-may .withvadvantage be replaced. by one of upon further heating with metals such ascopper,

for example, with greatease andrapidity. Copper melts at 1084 C. while the copper-beryllium eutectic alloy containing about 4.2% of B. melts at about 865 C. and the alloy with 12% of 136.

melts at 925 C. If the temperature of the bath is raised up to say 900 to 1020' C. the portion of copper lining 62 that is in contact with the.

spangles melts down at once to a' copper-beryl-i,

lium alloy while the copper part above the fused salt remains unchanged. For sampling, a heavy,

copper wire, with a loop on end, may be plunged down into the thick sludge of hot beryllium spangles inthe crucible 6|. If it is not withdrawn -'almost instantly after as the sodium tire clay. JAlso, the entire-system ,ofcrucibles may be replaced by acopper or nickel beaker.

Graphite for the crucible Si is very serviceable but crucibles-of magnesia,.alumina, magnesium aluminate, -.zirconla, ;highly .ignited beryllium oxide, beryllium aluminate and analogous compositions may-be used.

In large scale work, alloys may be made under such conditions that "the outside of the alloying metal is kept cool enough to remain solid and thus serve as crucibles that will not furnish contaminating impurities from-their walls- I may also take beryllium chloride vapor from the apparatus at or from the outlet 33 and chloride which become chilled on its cold sur-. i

face melts, the whole loop and lower end of thev copper quickly becomes alloyed with the spangles and melts away.

By using known weightsof sodium, beryllium salts and copper and guarding against losses by spattering or volatility, alloys of any predetermined composition can be readily made. It is very easy to get master copper-beryllium alloys containing 12% to 15% or more of beryllium at very reasonable temperatures.

Both the receptacles and the thin crucible 6| may be made of copper.-- Copper has inner bring it and sodium vaporinto reactions with or without diluent gases. These substances may be caused .to impinge against a mass of alloying metal to form an alloy which will drain away as liquid while the remaining metal itself remains solid. The two vapors of sodium and beryllium chloride may be caused to react under molten sodium chloride, etc., to form pure molten beryllium, or, with an alloying metal that is present to form alloys. when cuprous chloride is fed in gradually as the sodium is added it supplies the advantage of better heat conductivity over iron, is imperviou to hydrogen at a red heat and the outer surface can be kept free from oxide if the furnace gases are slightly reducing. -When a copperreceptacle 55 is used there is no danger; of insidious introduction of oxygen from the furnace through the walls of this receptacle to form water with hydrogen and thus cause con-' tamination of the beryllium spangles. When an iron receptacle 55 is used the danger of damage due to oxidation of iron may however be avoided by having the furnace gasesvery strongly re- -ducing or by surrounding the receptacle 55 W1 an atmosphereof hydrogen, etc.

part of the copper. and-at the same time by alloying with the beryllium the increased specific "gravity causes more prompt settling of the spangles. The following information'is given to enable the user of the process and apparatus of this inberyllium oxide retains or adsorbs water very.

tenaciously and that great care must be exercised if damage in chlorinating is to be avoided.

The other impurities likely to be present in beryllium oxide are silica, alumina, ferric oxide.-

lime, magnesia and sulphates. Silica is eliminated in the chlorination as the very volatile silican tetrachloride. Iron volatilizes very quickly as ferric chloride, sublimes out and can be removed before there is much action on the beryllium oxide. Aluminium chloride is also eliminated because it is much more volatile than beryllium chloride. Lime and magnesia are converted into non-volatile chlorides so that they with alkali or other non-volatile chlorides'remain as a harmless residues.

Despite great care it is practically impossible to wash out all sulphates from the basic carbonate when it has been precipitated from strong beryllium sulphate solutions. Also, because beryllium sulphate forms basic sulphates it becomes increasingly diflicult to expel 50:, as the ratio of the BeO increases, without heating to a temperature. high enough to make the oxide less reactive than is desirable.

By introducing a current of carbon monoxide into the retort not only are traces of sulphate and it fumed very strongly iii-moist air.

When, pure beryllium sulphate is introduced into the retort I and air is bubbled through warm water to saturate it with moisture'and it is then passed through theretort, copious, dense fumes of H2804 are evolved and at the end a little S02. Neither sulphur. nor H18 are evolved in appreciable amounts at 720 C.: The residue contains only a small amount of sulphates.

The presence of S0: opposes the reaction of converting BeSO4 to Bet) and therefore its ree moval is advantageous. It may be removed by reducing agents such as CO and H: to reduce the S0: to S02. 8 and Has. Water vapor alone is also helpful for this purpose. Heating alone will remove the sulphate group from beryllium carbonate but the'reduction may go too far and result in fixing some of the sulphur as a sulphide. When water vapor is added'to the reducing agent the beryllium sulphide is hydrolyzed to ms and Eat) (or beryllium hydroxide which atthe temperature 'used "breaks into water and BeO). I prefer to have the water and reducing agent act simultaneously but they'may alternate or the waremoved but pure beryllium sulphate is converted quantitatively into oxide at comparatively low temperatures. First, a large quantity of water is driven off, then some ammonia and ammonium salts, then sulphur dioxide, sulphur and hydroing. The resulting product contains'practically no sulphates, but will give an odor of hydrogen sulphide when heated with dilute acid. Dry hydrogen will give substantially the same result as dry carbon monoxide.

When pure BeSOrAHzO is'used in the retort I it is first dehydrated at about 220 C. and then heated in a current of dry carbon monoxide. Water is first expelled and at 450 C. very little H28 is noticed but at 650 C. ms is evolved copiously. Very little S or H2804 is formed but there is a large amount of SO: and ES. The white product contains practically no sulphate but on solution in acid'it gives a very strong odor of H28 thus showing the presence of a beryllium sulphide. Dry hydrogen gives substantially the same result.

when pure beryllium sulphate is introduced into the retort I and carbon monoxide bubbled through warm water so as to carry along moisture was passed through the retort, the products removed are some H1304, very much S02, some H28 and no sulphur. Some of these products are removed at a temperature below 500 C; At 650 C. the reaction is quite rapid while at 720 C., it is substantially complete. The purified product is somewhat resistant to solution in hydrochloric ter vapor may even be admitted after the reduction is completed to then decompose the sulphide with elimination of ms. I A verygreat variety'of reducing agents may be used to effect the elimination of sulphur as above described. Among the'cheaper ones are hydrogen; carbon monoxide; hydrocarbons; alcohols,

such as wood alcohol, ethyl alcohol, etc; aldehydes such as formic and-acetic; acids such as formic, acetic, etc ketones, such as acetone commercial gases'such as water gas, producer gas, etc. Evensulphur or sulphur containing substances such as CS: and H28 may be used'to reduce the S03.

I prefer ordinarilyto work at atmospheric pressure but the reactions can be carriedout at diminished pressures, or at pressures above at mospheric.

The reducing substances need not be gases or liquids as is the case with most ofthose above mentioned. Carbon, such as sugar 'charcoal sugar. starch, etc., are useful. This is particularly'the case when it is desired to use chlorine with a mixture of beryllium oxide and carbon for the preparation of the chloride. In this case I prefer to mix ash-free substances such as sugar, starch, carbon, etc., with BeO and then briquette the dry substances by pressure alone or I mayuse pressure plus slight heating in case of fusible substances such as sugar.

The process and apparatus described and the examples given serve merely as illustrations, and I do not wish to be limited by them as a large number of modifications within the scope of this invention will be obvious to one skilled in the This application is a continuation of my prior co-pending application, Serial No. 680,923, filed July 18, 1933.

I claim:

,11. The process which comprises heating an impure beryllium compound containing oxygen the impurity of. which is volatile 'upon heating and simultaneously passing a current-of gas containing carbon monoxide into contact therewith in the absence of reagents which would form volatile compounds of beryllium whereby imberyllium oxide is volatile upon heating and simultaneously passing intocontact therewith-a current of carbon monoxide free from reagents which react with beryllium oxide at the temperature of treat-- ment whereby impurities are-removed and purified beryllium oxide is obtained.

3. The process which comprises heating beryllium compounds of the class consisting-of carbonates and oxides and containing as impurities, ammonium and sulphate radicals and simultaneously passing into contact therewith at a temperature at which impurities are removed by volatilization, a current of gas containing free hydrogen free from reagents which react with beryllium oxide at the temperature oftreatment whereby purified beryllium oxide is obtained.

4. The process which comprises heating an impure beryllium compound containing oxygen the impurity of which is volatile upon heating and simultaneously passing a current of gas con- F taining carbon monoxideand water vapor into contact therewith whereby impurities are removed and purified beryllium oxide is obtained.

5. The process which comprises, heating bri-'* quettes of a beryllium compound containing oxygen and a volatile radical, removing volatile products by means of a gas current containing carbon monoxide free from reagents which would react with beryllium oxide at the temperature of treatment and treating resulting beryllium oxide with a halogenizing compound.

6. The process which comprises briquetting a beryllium compound containing oxygen and a volatile radical, heating said briquettes to a temperature at which volatile products are released,

removing volatile products by passing through thereto by condensation.

8. The process which comprises halogenizing beryllium oxide, removing vapors of halogenized beryllium, condensing them asa liquid, sepa-. rating the liquid from uncondensed gases, usingthe resulting body of liquid as a gastight seal for the liquid outlet from the condensing space, removing liquid from this body as more is added thereto by condensation and removing the uncondensed gases through another liquid seal.

9. The process which comprises halogenizing beryllium oxide in a heated zone, removing vapors of halogenized beryllium from an intermediate portion of said zone, condensing them as a liquid, using the resulting body of liquid as a gas tight seal for the liquid outlet from the condensing space, and removing liquid from this body as more is-added thereto by-condensation. 10. 'j The. process which comprises halogenizing beryllium 'oxide, removing vapors of halogenized beryllium,xcondensing them as a liquid and using o the liquid as agas-tight seal for the liquid outlet t .trom thexcondensing space anddistilling said liquid. 4

11. The :-process' which comprises "heating an r impure beryllium compound containing oxygen .10. and simultaneously a current: gas

' 'containing carbon monoxideand stamina con-- tact therewith whereby impurities 'are removed Ba nuriiiedberyluumo ide' s" b ained A 12. The process which compl isfesheating the is upper portion ot a column'of beryllium compound containing; oxygen and a: volatile radical and simultaneously; a current of carbon monoxide cohtaininggas' free from. reagentswhich would react with berylliuln oxide at the tem- 'perature of treatment through said. column, and heating the resulting mate'rial in". the lower portion of said column in the presencellof a haloenizin' 'g agent. f V 13., Zlhe process which;coinprisesheating the upper portion of 'a column ofberyllium compound containing oxygen and ajvolatile' radical and simultaneously a current ot'carbon monoxide containing g'as unougn said" column, and heating the resulting materiai'i n the'lower por- 80' non ofsaid'colulnri iwhilef-pa'ssing chlorine and carbon-monoxidetherethroug h. 14. The'p'rocess which comprises heating briquettes of a beryllium compound containing oxygen, removing volatile products by means of a gas current containing a carbon containing reducing agent free from reagents which would react with beryllium oxide at the temperature of treatment,-and treating resulting beryllium oxide with a halogenizing compound and a; educing agent.

15. The process which comprisesheating briquettes of a beryllium compound containing oxygen, removing volatile products by means of a gas current.containing .a hydrogen containing reducing agent free from'reagentswhich would react with beryllium oxide at the temperature of treatment, and treating resulting beryllium oxide withta halogenizing compound and a reducing agen.

16. The process which comprises heating briquettes 01' a beryllium compound containing oxygen; removing volatile products by means of a gas current containing a reducing agent, and treating resulting beryllium oxide while it is still ,hot with a gaseous current containing a halogen 5 compound and a reducing agent.

- 17. The process which comprises heating briquettes o! a beryllium compound containing oxygen, removing volatile products by means of a gas current containing a reducing agent and 60. water .vapor tree from reagents which would react with beryllium oxide at the temperature'bf treatment, and treating resulting beryllium oxide with la halogenizing compound and a reducing agent. 18; The process which comprises heating a 5 column of beryllium oxide, introducing chlorine and carbon monoxide into the lower portion of said mass, introducing chlorine and carbon monoxide intermediate the upper and lower portions of said mass, withdrawing volatile impuri- 7 ties from the upper portion 01' said mass, and withdrawing beryllium chloride between the points where the chlorine and carbon monoxide are introduced. 19. The process' which comprises reacting upon 45 beryllium oxide with chlorine in a heated zone 8 l and withdrawing impurities from a point above that at .which the chlorine is added, and withdrawing beryllium chloride thereby formed from a point below that at :which thelrnpurities areremoved and below the-top of theberyllium oxide where the temperature. is suiliciently high to volatilize the beryllium chloride.

20. The process which .Gmp1' i es heating bery1- compoundscontaining sulphate, andsimulta'n'eously passing, a current 01' gascontaining a reducing ageht-intocontact therewith at a temperature at which. the sulphate is decomposed with fformationloi beryllium oxide in which the therethrough .a current of gas which, does not. react with oxide in said temperature range until the material is substantially all converted to beryllium oxide, subjecting the resulting beryllium oxide in the form oi a cohesive but permeable briquette to a flow of gases adapted'to react therewith.

'22.f,'1he .process which comprises heating a material containing beryllium oxide and a combined volatile radical to substantially within the range 650 to 120 ,C., keeping the temperature frcmsubstantialLvexceeding said range, passing therethrough a currentof gas'which' does not react with beryllium oxide in-said temperature range until the beryllium oxideof the material is substantially entirely free from said volatile radical and a very reactive form of BeO .is produced, and chlorinating the resulting oxide by reaction with a gaseous chlorinating agent at a low red heat.

23. The process which comprises heating a material containing beryllium oxide and'a combined volatile radical to substantially within the range 650? to '720 C.,- keeping the temperature from substantially exceeding said range, passing therethrough a current of gas which does not react with beryllium oxide in said temperature range, until the beryllium oxide of the material is substantially entirely free from said volatile radical and a very reactive form of beryllium oxide is produced.

24. The process which comprises heating a Y material containing beryllium oxide and a combined volatile radical to substantially within the range 650 to 720 C., keeping the temperature from substantially exceeding said range, passing therethrough a current of a reducing gas which does not react with beryllium oxide in said tem perature range, until the beryllium oxide of the material is substantially entirely free from said volatile radical and a very reactive form of beryllium oxide is produced.

v I 7 ,JOHN E. BUCHER.

CERTIFICATE OF CORRECTION.

Patent No. 2 ',27O,502. M "Janua1 .w. 20,-1Qp2 'JOHI E. BUCH'ER;

It is hereby certified that error a ears i 1 1 the pfi-n tedispeo i fiogfiion. of the above numbered patent requiring correction asfo'lloyvsz" Page 7,5551}.

end-column, lines 51;, 11.2, 51 and 58', claime' tql'Y; befo i fefieifioving" inae'rt --and a volatile radical--; and that the-guid- Lettererll atept should -be read with this correction therein that the smile my oo hi'ofin to tihe fgre caid of the case in the Patent Office 1 Signed and sealed this 29th day of December, A. l94.2

. em Y iL- w i (Seal) Acting cozmn'issionen; of Patent s. 

